Method and means for forming continuous chair



Nov. 14, .1961 D. w. GODDARD 3,008,496

METHOD AND MEANS FOR FORMING CONTINUOUS CHAIR Filed July 29, 1957 2 Sheets-Sheet 1 INVENTUR D. W. GODDARD BYMI:

ATTY

Nov. 14, 1961 D. w. GODDARD 3,008,496

METHOD AND MEANS FOR FORMING CONTINUOUS CHAIR Filed July 29, 1957 2 Sheets-Sheet 2 INV E NTUR D. w. GODDARD United States Patent M 3,008,496 METHOD ANDv MEANS FOR FORMING CONTINUOUS CHAIR Douglas W. Goddard, 49 Lucy Ave, Toronto, Ontario, Canada Filed Jnly29, 1957', Ser. No. 677,810 7'Claims. (Cl..140-71) This. invention relates to an improved method and means. of manufacturing items for use in reinforced concrete known variously as slab spacers, continuous low chairs and beam bolsters.

'Such items comprisea length of wire carried by a plurality of legs formed by bending short lengths of wire into generally Uformat-ions, the legs being welded to the wire at intervalsalong its length. At present the legs are formed separately from the wire which is first straightened and then cut to the desired length. The legs are. then assembled in relation to the wire, for instance, by the usev ofa. suitablejig, but the parts are required to be indi-- vidually handled in the assembly, The legs are then welded tothe. wire to complete the operation;

The operation requires the services and different skills of several Workers, usually four, and production is slow and tedious; because of both the extensive handling of parts. and the number of operations.

The principal object of this invention is to provide a method. and means of automatically producing such slab spacers, continuous chairs, beam bolsters and the like, which. method will eliminate the requirement of the handling of separate parts and the. services of the skilled workmen previously required, to thereby enable produc tion rate to be increased tremendously and to provide a very substantial reduction in cost of manufacture.

The principal feature of the invention resides in feeding wire; crosswise} of a length of feeding wire, effecting stoppageof crosswisefeed. when the requisite length of wire corresponding toone part of a chair leg has fed across the-feeding Wire length, effecting stoppage of the feeding wire length when it hasfed past the crosswise Wire length afdistance corresponding-to thedesired legspacing, then simultaneously welding the stopped wires together and cutting off the cross fed wire at a distance from the wire leng'th corresponding tothe other part of the chair leg, then feeding the wire length with the cut cross fed wire welded thereto a distance corresponding to leg spacing. while simultaneously feeding a further wire length crosswise of thefeed -wire in preparation for the next Welding and cutting operation; and then subsequently shaping the previously attached cross fed welded and cut wire to form thechai'r leg. Preferably according, to the invention the shaping of tlie previously attached cross fed, welded, and cut'wire is effected simultaneously with the welding and cutting of thesubsequently cross fed wire. I

Another feature of the invention resides in utilizing. the

previouslyattached cross fed wire. as. the means to stop the feeding wire length at the desired point to provide requisite leg spacing and effecting release of the wire.- le'ngtjfor" subsequent feedi'ngjby the action of shaping suchcross fed'wire into'its leg formation.

Another feature of the invention resides in utilizing, a previously attached. and shaped leg aszthfi means. of initiatiuga subsequent cycle of. wlireweldihg cross fed wire cut oif; and, leg shaping to complete the automatic cycle; ofthemanllfacture.

accordingtothe invention the means for effecting cross fed wire length and, wire feed provide for adjustmentto afiord. controlofleg-size. and spacing as desired.

Still another feature resides in providing for the. autoz-- matic crimping of. the wire length towhich the legs are attached simultaneously with the welding, cut off, and leg formin'goperation.

3,008,496 Patented Nov. 14, 1961 These and other objects and features will become. apparent from the. following detailed description taken, in conjunction With the. accompanying drawings, in which:

FIGURE 1 is a part-diagrammatic, part-perspective: view illustrating the essentials of the apparatus for the production of continuous chair or the like inaccordance with the invention;

FIGURE 2 is a side-elevational View, partly broken away, of the apparatus;

FIGURE 3 i518 transverse sectional view on the line 3-3=of;FIGURE 1;v

FIGURE 4 is a part-perspective, part-diagrammatic view illustrating one stage in the forming of the continuous ch air;

FIGURE 5. isa view similar to FIGURE 4, showing a: further stage in the formation of the continuous chair in which wire feed has been interrupted;

"FIGURE 6 is a further part-diagrammatic perspective view illustrating the relationship of the parts to effect wire Welding and leg shaping subsequent to the stoppage of wire feed shown in FIGURE 5;

FIGURE 7 is a view similar to FIGURE 6, but showing the relation of the parts to complete wire welding andleg forming;

FIGURE. 8 is a fragmentary elevational View of the rant control of' the apparatus, showing the relationship for ram descent; v 7

FIGURE 9 is a view similar to FIGURE 8, but showi-ng the relationship ofthe parts to render ram inoperative;

FIGURE 10 is a fragmentary elevational view showing the manner in which control of the electric Welder is effected;

Referring first to FIGURES 1 and 2, the apparatus for producing continuous chair, slab spacers or beam bolsters according to the invention comprises a stationary platform 1' on which are arranged a number of components, and a movable platform 2 on which are arranged a number of cooperating components. Conveniently, the platform]; may be the bed of platform of a conventional press, and the movable platform 2 may comprise the ram or'head of the press.

Mounted on the platform or bed I centrally thereof is one electrode 3 of'a pair of welding electrodes. The cooperating electrode 4 is spring mounted on the movable platform or ram 2 by means of suitable springs 5, with the movement of the electrode 4 being guided by suitable guide pins 6. V

' Arranged at one side ofthe press is a wire feed mechanism designated'at 7-, which comprisestwo continuously driven friction rolls 8 urged together under the action of a spring 91o feed a wire 10 drawn ofia spool or reel 11' and through a wire straightener 1-2; The wire feed mechanism; under frictional forces exerted through the rolls 8, maintain frictional feed on the wire-to advance it across the bed of the press until the wire meets an obstruction and is stopped thereby; Arranged on the bed or platform 1 of the press in alignment with the electrode 3 and the wire-feed mechanism 7 is one crimping jaw member 13 while the platform or ram 2 carries acooperating crimping'jaw member--14; It wilI be understood, however, that thesecrimping jaws maybe omitted 'i-fthe end product is to have: a straight body length.

Arranged onthe' opposite side of the electrode 3 from the crimping jaw 1:3 is aplate 15 carried by an arm 16 which-is mounted for adjustment on a support bar 17 to enable the plate 15=to be adjusted towards and from'the electrode 3'. This plate 15 has a notch 18 cut in the underside thereof, the notch having a somewhat bell-like shape narrowing to a part-circular groove-like upper portion 19;- The arrangement of parts is such that the groove 19' is in alignment with the path of wire feed, and the wire 10 passes therethrough until a transverse wiresection 20, attached thereto in a manner as hereinafter explained, reaches the plate 15, whereupon feed of wire is interrupted despite urging under the action ofrolls 8.

Immediately in front of the plate is arranged one forming member 21 of a cooperative pair of formers which are arranged to shape the wire section into the desired shape here illustrated as a generally inverted U or hell shape to form the chair leg. The other forming member 22 is mounted on the ram 2, and the members 21 and 22 are adjustable towards and from the electrodes 3 and 4 in conjunction with the plate 15.

Disposed behind the platform 1 is a second pair of feed rolls 23 similar to the rolls 8 which are arranged to feed a wire 24 drawn from a reel and through a straightener, not shown, similar to the reel 11 and straightener 12, crosswise of the wire 12 above the stationary electrode 4 and against a stop 25 which is disposed in right-angular relation to the stop plate 15 and can be adjusted towards and from the electrode 3. As shown, the wire 24 is fed beneath the wire 10 and is disposed in right-angular relation thereto.

The wire 24, in feeding above the electrode 3 and against the stop 25, passes over a spring mounted cut oif die member 26, slidabl y mounted between uprights 27. The assembly comprising the die member 26 and uprights 27 is adjustably mounted on the platform 1 for movement towards and from the electrode 3. Mounted on the moving platform or ram 2 is a cooperating cut-off die member 28 which, on descent of the ram, is adapted to cut off a transverse wire section 20 from the wire 24. It will be noted again that the wire 24 is continuously under feeding pressure, and interruption of feed is efiected by its end contacting stop 25.

The descent of the ram may be controlled through any conventional clutch mechanism, the details of which will be well known to those skilled in the art. The means of controlling this clutch mechanism is shown in FIG- URES 8 and 9, and comprises an arm 29 connected to the clutch mechanism through suitable linkage 30 and operated by the piston 31 of a solenoid operated cylinder 32. A solenoid 33, when energized, is arranged to effect descent of the piston 31 to throw in the clutch mechanism and efiect descent of the ram or moving platform 2.

The piston 31 carries an arm 34 which is adapted on descent of the piston 31 to engage a micro switch 35 to operate the air cylinder 32 to return the piston 31 upwardly, declutching the ram when it is returned to its upper position to prevent operation thereof until the solenoid 33 is again energized to initiate a further ram stroke.

Energization ot the solenoid 33 to effect descent of the ram is achieved by means of a micro switch 36 adjustably mounted along the path of the wire 10 beyond the stop plate 15, the switch being shown as slidable on a. bar 37 and carrying a contact roller carrying arm 38 disposed in the path of a chair leg 39 as shown in FIGURE 1 after the wire section 20 has been formed into the leg, whereupon it is free to pass through the notch 18 in the plate 15, allowing feed of wire 10 to recommence.

The cross fed wire 24 is welded to the wire 10 on descent of the ram to close the electrodes 2 and 3 on these wires by means of passing high current between the electrodes.

and through the wires, the current being obtained from a conventional welding machine 40 indicated in FIGURE 10. To this end, the upper electrode 3 is connected to the highvoltage terminal of the machine through a suitable conductor strip 41, and the moving platform or ram of the press 2 carries a bracket 42 which, on descent of the ram, depresses a bar 43 operating the welding machine treadle 44 to set the welding circuit for the weld.

Operation With reference to FIGURE 1, and particularly FIG- URES 4 to 7, and assuming to start the operation a wire section 20 has previously been welded to the underside of the wire 10 with the moving platform or ram 2 raised, the wire 10 feeds forwardly until the wire section 20 strikes the plate 15, stopping wire feed. While wire 10 is feeding, wire 24 is feeding crosswise of wire 10, until it strikes stop 25. and wire feed is then interrupted. Assume that rmcro switch 36 is now operated, causing the piston 31 of air cylinder 32 to descend. This action will bring about the descent of the moving platform or ram 2. On descent of the ram, the welding machine 40 is readied for the weld of wires'20 and 24, and as the ram reaches the bottom of its stroke, weld of these wires is effected. Simultaneously, cutoff die members 26 and 28 cooperate to cut off a short length of wire from the end of the wire 24 to form a transverse wire section 20.

Also simultaneously, the forming members 21 and 22 cooperate to form the previously welded wire section 20 at the plate 15 into a chair leg 39, and where the crimping jaw members 13 and 14 are employed, a crimping of the wire 10 in advance of the electrodes will also simultaneously be effected. As the ram reaches the bottom of its stroke, the arm 34 carried by the piston 31'of air cylinder 32, will have actuated micro switch 35 to declutch the ram from its driving mechanism so that the ram, after it has returned to its raised positioned to complete its stroke, will be rendered inoperative from making a subsequent stroke until micro switch 36 is again energized.

As the platform or ram 2 moves upwardly to complete its stroke, the leg 39, which has been shaped between the forming members 21 and 22, will be released, and since it is now a shape to pass through the notch 18, the wire 10, under urging of the continuously operating drive rolls 8, will feed forwardly, and the wire section 20, which has just been previously cut off and welded to the wire 10, will be fed towards the plate 15. As this wire section 20 clears the electrode 3, the wire 24 will be free to feed under the drive of the continuously rotating rolls 23, until the end thereof again reaches stop 25.

Prior to the wire section 20, which has just been cut off end welded, reaching stop plate 15 to interrupt feed of the wire 10, the =leg 39, which has just previously been shaped, strikes the arm 38 to actuate micro switch 36, and again, energize solenoid 33 to initiate the ramcycle again to repeat the sequence of events above described.

It will thus be appreciated that the operation, once initiated, automatically continues so that an indefinite length of crimped wire 10 carrying legs 39 can be formed. A suitable cut-off die 45 may be provided to cut off desired lengths of chair, as shown in FIGURE 2.

Since the plate 15 is adjustable to and from the electrodes, it will be understood that the spacing between the chair legs 39 can be adjusted as desired. Also, since both the stop 25 and the cut-off members 26 and 28 are both adjustable towards and from the electrodes, the length of the transverse wire sections 20, which are welded to the wire 10, can be adjusted as desired. While the stop 25 and cut-off die members 26 and 28 are described above as being of equal distance from the electrodes, so that the wire section 20 is welded at its center to the wire 10, it will be understood that they may be independently adjustable to provide any desired ratio of lengths of the wire 20 on opposite sides of the wire 10. That is, the chair leg need not be secured at the center to the wire 10, and the part on one side of the wire 10 may be greater or smaller than the part on the opposite side.

As the length of the wire section 10 is selected, it will be understood that the size of the chair legs 39 will be determined, and of course, the forming members 21 and 22 can be replaced as desired to provide any desired change in configuration of the legs. It will also be understood that the plate 15 may be modified as desired to alter the configuration of the notch or recess 18 to correspond to the desired shape of chair leg.

It will be understood that various modifications .and alternations and arrangements in details will be apparent to those skilled in the art, and such modifications and alterations may be made within the spiritpf the invention without departing from the scope of the appended claims.

What I claim as my invention is:

1. A method of forming continuous chair or the like comprising feeding a principal wire in a substantially straightdine path and simultaneously feeding a secondary wire cross-wise of said principal wire, stopping cross-wise feed when suflicient length of said secondary wire has been fed across said principal wire to form one part of a chair leg, stopping feed of said principal wire when a length corresponding to desired leg spacing has been fed beyond said secondary Wire and then simultaneously effecting welding of said principal and secondary wires together and severing said secondary wire at a point spaced from said principal Wire of sufficient length to form the other part of a chair leg, then recommencing feed of said principal wire in the straight-line path with said first severed length of secondary wire attached thereto, and simultaneously recommencing feed of said secondary wire cross-Wise of said principal wire, the feed of said secondary wire being continued until a length thereof sufiicient to form one part of a chair leg has been fed across said principal Wire and the feed of said principal wire being continued in the straight-line path until a length thereof corresponding to desired leg spacing has been fed beyond said secondary wire and then, simultaneously, shaping said first severed length of secondary wire into a chair leg, welding said principal wire and secondary wire together and severing said secondary wire at a point spaced from said principal wire of sufiicient length to form the other part of a chair leg and so repeating.

2. A method as claimed in claim 1 in which said principal wire is cn'mped at a point in advance of the point of cross feed of said secondary wire.

3. A method as claimed in claim 2 in which said crimping is eifected simultaneously with said welding operation, severing operation, and chair leg shaping.

4. A method as claimed in claim 1 in which the first severed length of secondary wire is utilized as the means to stop feed of said principal wire at the desired point for the subsequent welding of said principal and secondary wires.

5. A method as claimed in claim 4 in which the shaping of said first severed length of secondary wire is utilized to effect release of said principal wire for subsequent straight line feed.

6. In the forming of continuous chair and the like comprising the step of feeding a continuous length of wire maintained under continuous feeding frictional been previously welded to extend transversely thereof to bring said transverse wire length against a first stop a predetermined distance beyond a welding station and simultaneously cross feeding a Wire maintained under continuous feeding frictional forces to feed transversely of said continuous length of wire at said welding station against a second stop disposed beyond said continuous length of wire in respect of cross fed direction a distance corresponding to one part of the length of a desired chair leg, then simultaneously Welding said cross fed wire to said continuous wire length, cutting off said cross fed Wire on the side of said continuous Wire opposite to said second stop at a point :a distance from said continuous wire corresponding to the length of the other part of a desired chair leg, and deforming said short transverse wire length to form a chair leg and to clear said first stop, said continuous feeding friction forces thereupon acting to feed said continuous wire with said cut off cross fed wire welded thereto until said latter wire engages said first stop and to feed said cut cross fed wire to bring the cut end thereof against said second stop and so repeating.

7. A method as claimed in claim 6 in which said transverse deformed wire is employed to initiate said welding and said cross fed Wire cut off.

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